Method and system for a foldable structure employing material-filled panels

ABSTRACT

In one embodiment, the present invention can include a foldable structure employing material-filled panels which can be used as an emergency shelter in disaster areas. A building can formed from one or more building blocks. The building blocks can be in a compact position, such as when being transported to a disaster area, or in an expanded position, such as when the building is ready to be built in the disaster area. In the expanded position, the building blocks can be filled with various materials such as expanding foam material. The expanding foam material can be formed from two mixing materials. In addition, the expanding foam material can have insulating properties. The building of the present invention can also be used, for example, as sheds, tree houses, and/or permanent housing. The building blocks can have marine applications and/or military application due to their light weight, yet, ballistic nature.

RELATED APPLICATIONS

This application claims the benefit of provisional application No.61/219,281 entitled “FOLDABLE BUILDING STRUCTURE EMPLOYING FOAM-COREBUILDING PANELS” filed on Jun. 22, 2009, and which is expresslyincorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Disclosure

The present disclosure generally relates to a method and system for afoldable structure employing material-filled panels.

2. Description of the Related Art

Each year natural disasters such as earthquakes, tornados, floods,tsunamis, storms, and/or hurricanes occur in areas all over the world.These natural disasters are often unpredictable, terrifying, anddevastating causing millions of dollars in damage and tremendous loss oflife. The first hours and days of a natural disaster are critical torelief workers when attempting to mitigate the damage and casualties ofthe natural disaster area. However, the relief workers often have littleto no place to stay due to the damage caused by the natural disaster tosuitable shelters such as hotels, vacant apartments, or houses. Inaddition the displaced native population will generally utilize anyvacancies in housing. Moreover, to the extent that the natural disasterdamages houses, apartments and hotels belonging to the nativepopulation, this displaced native population will also be in dire needof suitable shelter.

Because the building of even temporary housing is time consuming andexpensive and can require, for example, natural resources which may notbe readily available in the area affected by the natural disaster, thecritical first hours and days of the natural disaster, are either wastedbuilding housing for the relief workers rather than the displaced nativepopulation or are spent erecting temporary shelters that typically donot provide a long term solution for the displaced native population.

In the meantime, the critical first hours and days are not usedefficiently since a limited amount of relief workers will be present,and furthermore, energy is wasted building housing for the limitedamount of relief workers. This can lead to a high amount of damages andcasualties.

Temporary solutions such as tents are generally unsatisfactory sincethey may not provide adequate shelter against extreme temperatures atnight or the day. In addition, such temporary solutions are generallyuncomfortable, which can fatigue and tax the rescue workers. This canreduce the efficiency of the rescue workers. In addition to naturaldisasters, additional housing may be needed during military conflictsand/or during peacekeeping missions. Temporary solutions are alsogenerally undesirable during such problematic issues.

More permanent temporary shelters are typically expensive both in termsof the purchase price and to transport to the location of the naturaldisaster. Thus, there is a need for a building which can be easilyerected in an efficient manner while providing a comfortable andadequate shelter.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed, for example, to a building which canbe easily erected in an efficient manner while providing a comfortableand adequate shelter. In one embodiment, the present invention can be afoldable structure employing material-filled panels which can be used asan emergency shelter in disaster areas.

The present invention can be, for example, a building formed from one ormore building blocks. The building blocks can be in a compact position,such as when being transported to a disaster area, or in an expandedposition, such as when the building is ready to be built in the disasterarea. In the expanded position, the building blocks can be filled withexpanding foam material. The expanding foam material can be formed, forexample, from two mixing materials, allowing for the easy generation ofthe expanding foam material. This reduces the amount of naturalresources used to erect the building. In addition, the expanding foammaterial can have insulating properties to provide adequate shelteragainst extreme temperatures during the day or night. The buildingblocks can also be formed, for example, from other types of materialssuch as cement, organic material, rubble, earth, adobe, plant matter, orany type of local material. Thus, the building of the present inventioncan be easily deployed to a natural disaster area, and can be easilyerected without a huge tax on the natural resources. This can allow alarge number of buildings to be for relief workers in an efficientmanner. This can also increase a number of housing available for victimsand/or relief workers. This can provide immediate housing for thevictims and also increase the number of relief workers available duringthe critical first hours and days of a natural disaster. The presentinvention can also be permanent housing for the victims. In addition,during military conflicts, the present invention can provide housing,for example, for refugees. For peacekeeping missions, the presentinvention can house the peacekeepers.

In addition, the present invention is sturdy enough such that when therelief workers are not needed anymore, the buildings can provide shelterfor any displaced native population, reducing the recovery time period.The building of the present invention is also not limited to theemergency shelter, but can also be used, for example, as storage sheds,field hospitals, tree houses, and/or permanent housing. In addition, thebuilding blocks can have marine applications and/or military applicationdue to their light weight, yet, durable and ballistic nature.

In one embodiment, the present invention is a building block including afirst panel, a second panel opposing the first panel, and a plurality ofstringers connecting the first panel and the second panel, wherein thefirst panel, the second panel, and the plurality of stringers areconfigured to switch between a compact position and an expandedposition.

In another embodiment, the present invention is a building including aplurality of building blocks, each of the building blocks including, afirst panel, a second panel opposing the first panel, and a plurality ofstringers connecting the first panel and the second panel, wherein eachof the building blocks is configured to switch between a compactposition and an expanded position.

In yet another embodiment, the present invention is a building kitincluding a building block in a compact position, a roof in a compactposition and configured to be connected to the building block, a firstmixing material, and a second mixing material, the first mixing materialand the second mixing material selected such that a mixture of the firstmixing material and the second mixing material forms an expandable foammaterial which can be placed within the building block.

In still another embodiment, the present invention is a method forconstructing a building including transforming a first building blockfrom a compact position to an expanded position, placing supportmaterial in a support material area in the first building block,transforming a second building block from a compact position to anexpanded position, and connecting the first building block with thesecond building block.

In still yet another embodiment, the present invention is a method forconstructing a shed including transforming only a single building blockfrom a compact position to an expanded position, placing supportmaterial in a support material area in the building block, transforminga roof from a compact position to an expanded position, and connectingthe roof to the single building block.

BRIEF DESCRIPTION OF THE DRAWINGS

The exact nature of this invention as well as other objects andadvantages thereof will be readily apparent from consideration of thefollowing specification in conjunction with the accompanying drawings inwhich like numerals designate like parts through the figures thereof andwherein:

FIG. 1 is a perspective view of a building according to an embodiment ofthe present invention;

FIG. 2 is a side view of an outer panel and inner panel connected bystringers according to an embodiment of the present invention;

FIG. 3 depicts a portion of an outer panel according to an embodiment ofthe present invention;

FIG. 4 is a perspective view of a building including a roof according toan embodiment of the present invention;

FIG. 5 is a perspective view of a building block in a compact positionaccording to an embodiment of the present invention;

FIG. 6 is a perspective view of a building block in an intermediateposition according to an embodiment of the present invention;

FIG. 7 is a perspective view of a building block in an intermediateposition according to an embodiment of the present invention;

FIG. 8 is a perspective view of a building block in an expanded positionaccording to an embodiment of the present invention;

FIG. 9 is a perspective view of a building block according to anembodiment of the present invention;

FIG. 10 is a perspective view of a building block attached to a flooraccording to an embodiment of the present invention;

FIG. 11 is a perspective view of a building block partially filed withexpanding foam material;

FIG. 12 is a is a perspective view of a building block filled withexpanding foam material;

FIG. 13 is a building according to an embodiment of the presentinvention;

FIG. 14 depicts a snap together connection of two outer panels of twobuilding blocks according to an embodiment of the present invention;

FIG. 15 depicts a snap together connection of two outer panels of twobuilding blocks according to an embodiment of the present invention;

FIG. 16 depicts a snap together connection of two outer panels of twobuilding blocks according to an embodiment of the present invention;

FIG. 17 is an interlocking building unit according to an embodiment ofthe present invention;

FIG. 18 is a column unit according to an embodiment of the presentinvention;

FIG. 19 depicts interlocking building units connected to each otheraccording to an embodiment of the present invention;

FIG. 20 depicts a building block formed by interlocking building unitsaccording to an embodiment of the present invention;

FIG. 21 depicts a folding section in a compact position according to anembodiment of the present invention;

FIG. 22 depicts a folding section in an expanded position according toan embodiment of the present invention;

FIG. 23 depicts a folding section according to an embodiment of thepresent invention;

FIG. 24 depicts a folding section between an expanded position and acompact position according to an embodiment of the present invention;

FIG. 25 depicts a folding section in a substantially compact positionaccording to an embodiment of the present invention;

FIG. 26 depicts a folding section laid out in an open position accordingto an embodiment of the present invention;

FIG. 27 depicts a roof according to an embodiment of the presentinvention;

FIG. 28 depicts a roof according to an embodiment of the presentinvention;

FIG. 29 depicts a roof according to an embodiment of the presentinvention;

FIG. 30 depicts a roof according to an embodiment of the presentinvention;

FIG. 31 depicts a building according to an embodiment of the presentinvention;

FIG. 32 depicts a building block according to an embodiment of thepresent invention;

FIG. 33 depicts roof anchors according to an embodiment of the presentinvention;

FIG. 34 depicts a building including inserts according to an embodimentof the present invention;

FIG. 35 depicts a building including drains according to an embodimentof the present invention;

FIG. 36 depicts a process according to an embodiment of the presentinvention;

FIG. 37 depicts a process according to an embodiment of the presentinvention; and

FIG. 38 depicts an outer panel of a building block according to anembodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the preferred embodiments of theinvention which set forth the best modes contemplated to carry out theinvention, examples of which are illustrated in the accompanyingdrawings. While the invention will be described in conjunction with thepreferred embodiments, it will be understood that they are not intendedto limit the invention to these embodiments. On the contrary, theinvention is intended to cover alternatives, modifications andequivalents, which may be included within the spirit and scope of theinvention as defined by the appended claims. Furthermore, in thefollowing detailed description of the present invention, numerousspecific details are set forth in order to provide a thoroughunderstanding of the present invention. However, it will be obvious toone of ordinary skill in the art that the present invention may bepracticed without these specific details. In other instances, well knownmethods, procedures, components, molding procedures have not beendescribed in detail as not to unnecessarily obscure aspects of thepresent invention.

In one embodiment, the present invention includes a building 100 asseen, for example, in FIG. 1. The building can be, for example, a house,a shed, a tree house, a storage unit, a geodesic dome, and/or any othertype of structure which requires a relatively short build time. Thus,the building 100 can be easily built to provide, for example, housingfor relief workers or displaced persons in disaster areas. The building100 can also be, for example, easily built as a shed for personal use ina backyard. The building 100 can also be, for example, easily used as atree house for children and/or adults.

The building 100 can be constructed from, for example, a building block116. The building block 116 can be formed from an outer panel 102, andan inner panel 104. The outer panel 102 can oppose the inner panel 104.However, the outer panel 102 and the inner panel 104 need not beparallel with each other, but instead can merely just face each other. Aplurality of outer panel 102 and a plurality of inner panel 104 canform, for example, an outer shell 172 and an inner shell 174. The outerpanel 102 and the inner panel 104 can be formed, for example, fromplastic, polyurethane, polycarbonate, cardboard, UV resistant material,anti-microbial material, or any other type of lightweight, yet durablematerial. In one embodiment, the outer panel 102 and/or the inner panel104 can be treated to make them UV-resistant, anti-microbial,water-resistant, water-proof, sound-resistant, and/or sound-proof. Inaddition, the outer panel 102, and/or the inner panel 104 can be treatedwith fire-resistant material. The inner shell 174 can define, forexample, a usable area 120. The usable area 120 can be habitable and/orable to store materials. Thus, the usable area 120 can provide a spacefor one or more person to sleep in the usable area 120 or leavematerials in the usable area 120.

The outer panel 102 and the inner panel 104 are connected by a pluralityof stringers 108. The outer panel 102, the inner panel 104, and thestringers 108 define a support material area 106. The support materialarea 106 can be filled, for example, with support material 110. Thesupport material 110 can provide, for example, support for the building100. The support material can be, for example, expanding foam material,sand, dirt, rocks, sawdust, wood, straw, hay bales, rubble fromdestroyed buildings in disaster areas, other natural resources which maybe abundant or easily usable at a location of the building 100, and/orany combination of the above. In one embodiment, the natural materialcan be, for example, fire resistant, or develop to be fire resistant.For example, hay bales can be mineralized with nitrogen, which is fireresistant and is a good insulator.

Since the support material can be easily formed, such as in the case ofthe expanding foam material, or is constructed from abundant material,such as in the case of the natural resources, the building 100 can bebuilt in a relatively inexpensive manner without costly materials andlittle effort. The support material area 106 can have a width, forexample, of 8 inches or more. However, the width can be reduced orincreased depending on the type of support material 110 used and/or thetype of material used for the outer panel 102 and/or the inner panel104. Furthermore, the width can be reduced or increased depending on thetype of uses for the building 100.

The outer panel 102 and the inner panel 104 connected by stringers 108can be seen, for example in FIG. 2. As seen in FIG. 2, the stringers 108span the support material area 106. The stringers 108 provide supportfor the support material 110. In addition, the number of stringers 108provided can be large enough such that failures of some of the stringers108 will not substantially compromise the integrity of the building 100.The stringers 108 can be formed, for example, from dowels, plastic rods,twisted wires, a plurality of strong filaments or strips, zip ties,Kevlar® wires, kite strings, baling wires, nylon cords, metal piping,and/or other material suitable for supporting the support material 110.

In one embodiment, the stringers 108 can include a stringing unit 162and loops 164 at the end of the stringing unit 162. The stringing unit162 traverses the support material area 106. The loops 164 are formedoutside of the support material area 106. The loops 164 can be connectedto the outer panel 102 and/or the inner panel 104 by placing a wire 166through the loops 164. This can be seen, for example, in FIG. 3 with thewire 166 running through the loops 164 along a side view of the outerpanel 102. The wire 166 can be, for example, located on an inside oroutside side of the outer panel 102.

Instead of using the wire 166, dowels, rods, or any other type ofmaterial can be used. In addition instead of using the wire 166 or theloops 164, the stringers 108 can be connected to the outer panel 102and/or the inner panel 104 by being sewn onto the outer panel 102 and/orthe inner panel 104, using a Chicago screw, or any other type ofsuitable method.

Referring back to FIG. 2, the inner panel 104 can also optionally have aballistic material 168 adhered to the inner panel 104 and/or the outerpanel 102. The ballistic material 168 can be, for example, an Aramidfabric layer, Kevlar® layer, E-glass, ceramic material, and or any othertype of ballistic material which have ballistic properties. Theballistic material 168 can provided, for example, penetration protectionto the building 100. In addition, should the building 100 suffer anexplosion, the ballistic material can reduce the likelihood of damagingshrapnel emanating from the building 100.

Referring back to FIG. 1, conduits 112 can also be formed inside thesupport material area 106. The conduits 112 can be used, for example, todrain material from a roof, or provide a location for safe passage ofpipes and/or wires. In addition, the conduits 112 can also be used, forexample, for venting.

In one embodiment, the building 100 can include a floor 122 and/orwindows 114. The floor 122 in FIG. 1 is attached to the building block116 as foldable panels which can be folded into place to form the floorfor the building 100. However, other flooring can be used, such as awood flooring, a concrete flooring, tarp, flooring made from localmaterials, or any other type of flooring. In addition, the building 100can be anchored to the ground using, for example, a foundation anchorattached to the building 100.

The windows 114 can be formed, for example, by cutting through the outerpanel 102, the inner panel 104, and/or the stringers 108 after thesupporting material 110 has been deposited into support material area106. In the case where the supporting material 110 is expanding foammaterial, the expanding foam material, will have already set, allow foreasy creation of the windows 114. In one embodiment, the windows 114 canbe formed before the supporting material 110 has been deposited intosupport material 106. In another embodiment, the windows 114 can bepre-cut and/or pre-formed.

As seen in FIG. 4, the building 100 can also include, for example, aroof 118. In one embodiment, the roof 118 can be attached to thebuilding block 116 as foldable panels which can be folded into place toform the roof of the building 100. However, other types of roofing canbe used, such as roof tiles, wood, branches, and/or any other type ofroofs formed from local materials.

In one embodiment, the building block 116 can be configured to switchbetween a compact position and/or an expanded position as seen in FIG.5, FIG. 6, FIG. 7, and/or FIG. 8. As seen in FIG. 5, the building block116 is in a compact position with the outer panel 102 bent at thecorners 148 and in a flat position. The inner panel 104 can also be in aflat position and can be located inside the outer panel 102.

The building block 116 can also be switched to an expanded position asseen in the intermediate positions FIG. 6 and FIG. 7. In FIG. 6 and FIG.7, the building block 116 is transformed from its flattened position andthe outer panel 102, and/or the inner panel 104 is no longer flat, butinstead begins to define the usable area 120, and/or the supportmaterial area 106. The building block 116 is in the expanded position inFIG. 8. Although the building block 116 is formed in the shape of asquare or rectangle, the expanded position can be, for example, anyshape. In one embodiment, the position depicted in FIG. 6 or FIG. 7could be considered, the expanded position.

In one embodiment, the building 100 can be formed, by a series ofbuilding blocks 116 instead of only a single building block. Forexample, as seen in FIG. 9, a building block 116 a can be first placedon the floor 122 in an expanded position. In FIG. 9, the building 100can be attached to a floor 122 formed, for example, from concrete orsteel. In the case where the support material 110 is an expanding foammaterial, the building 100 can be attached to a floor 122 by letting theexpanding foam material expand and leak out of the building block 116 aand form a bond with the floor 122. In FIG. 9, the floor 122 is notflaps formed from the building block 116 a, but instead is a separateitem.

In one embodiment, as shown in FIG. 10, the building block 116 a can beattached to the floor 122 through a base plate 168. The base plate 168can include a receiving area 164 for receiving the building block 116 a.The base plate 168 can be attached to the floor 122 prior to receivingthe building block 116 a. After receiving the building block 116 a, thebase plate 168 can be attached to the building block 116 a usingconnecting units 166. Connecting units 116 can be, for example, studs,screws, fasteners, nails, or any other types of devices which canconnect two devices together.

Referring back to FIG. 9, the support material 110 is an expanding foammaterial 124. To form the expanding foam material 124, a first mixingmaterial 150 is added with a second mixing material 152 in a bucket 128.The resulting expanding foam material 124 is poured onto the supportmaterial area 106 as seen, for example in FIG. 11 and FIG. 12. Theexpanding foam material 124 begins expanding and substantially completesits expansion before it substantially sets, as seen in FIG. 12. Forexample, the foam material 124 can substantially complete rising beforeit substantially sets. This can reduce, for example, an amount ofpressure exerted on the outer panel 102 and/or the inner panel 104 andreduce an amount of bulging on the outer panel 102 and/or the innerpanel 104. Excess expanding foam material 132, or expanding foammaterial 124 that spills out of the building block 116 can be removed asseen in the portion 134 through sawing or other removal methods. In oneembodiment, the expanding foam material 124 can be a slow setting typeof foam which can take, for example, 5 minutes or more to set. Thequickness of the set time may not be critical since a set time which islonger than normal will generally still be faster than constructing abuilding 100 using conventional methods. In one embodiment, one inch ofexpanding foam material 124 when initially prepared through mixing thefirst mixing material 150 and the second mixing material 152 cangenerate between a 20 inch to 30 inch expanding foam material 124 whenthe expanding foam material 124 has finished expanding and has set.However, in another embodiment, one inch of expanding foam material 124can generate any amount of expanding foam material such as less than 20inches of expanding foam material 124 or more than 30 inches ofexpanding of foam material 124 such that it can provide adequatematerial for the building 100.

Once the building block 116 a has its expanding foam material 124 setand any excess expanding foam material 132 removed, building block 116 bcan be placed on top of the building block 116 a. The process forplacing expanding foam material in the building block 116 a can berepeated for the building block 116 b. In one embodiment, to secure thebuilding block 116 a to the building block 116 a, ribs 156 a, 156 b, 158a, and 158 b can be used as shown in FIG. 14, FIG. 15, and FIG. 16.

FIG. 14 depicts a cross-section of an outer panel 102 a for the buildingblock 116 a and an outer panel 102 b for the building block 116 b, whichcan be snapped together. The outer panel 102 a and the outer panel 102 bcan be, for example, an approximately 0.5 inch twin-wall sheet stockthat is formed from plastic. Although the outer panel 102 a and/or theouter panel 102 b are depicted, the inner panels can be used in the samemanner. The outer panel 102 a includes, for example, the rib 156 a, therib 158 a, an inner side 160 a and an outer side 161 a, while the outerpanel 102 b includes, for example, the rib 156 b, the rib 158 b, aninner side 160 b and an outer side 161 b. The rib 156 a and the rib 156b are shorter than the rib 158 a and the rib 158 b, respectively. Therib 156 a and the rib 156 b do not extend all the way across the outerpanels 102 a and 102 b, and instead is connected only on one end to theouter panels 102 a and 102 b. For example, the rib 158 a extends acrossthe inner side 160 a and the outer side 161 a, while the rib 158 bextends across the inner side 160 b and the outer side 161 b. However,the rib 156 a does not extend across the inner side 160 a and the outerside 161 a, and the rib 156 b does not extend across the inner side 160b and the outer side 161 b. The outer panel 102 a and the outer panel102 b can be placed together as indicated by the arrow 164.

As seen in FIG. 15, the rib 156 a and the rib 156 b bend as they touchand force is exerted on them. As seen in FIG. 16, eventually the rib 156a and the rib 156 b slide past each other, forming a lock to couple theouter panel 102 a to the outer panel 102 b. Even if the outer panel 102b was lifted straight up, the rib 156 a and the rib 156 b would contacteach other and provide resistance for such a movement. This reduces thelikelihood that outer panels 102 a and/or 102 b will be dislodged fromeach other. Furthermore, the outer panel 102 b now rests on the rib 158a, while the rib 158 b prevents the outer panel 102 a from sliding pastthe rib 158 b. The use of the ribs 156 a, 156 b, 158 a, and 158 b canprovide an effective and low-cost option for connecting the outer panel102 a to the outer panel 102 b, and the building block 116 a to thebuilding block 116 b. The same principles can be applied, for example,to the inner panels 104 for the building block 116 a and the buildingblock 116 b.

Referring back to FIG. 13, once the building block 116 b is attached tothe building block 116 a, the building block 116 c can be attached tothe building block 116 b. The roof 118 can then be attached to thebuilding block 116 c. In one embodiment, the building block 116 c doesnot have a uniform height, but instead is slanted to allow the roof 118to be slanted. The roof 118 can include, for example, a base unit 128,and a cover 130. The cover 130 can be overlayed on top of the base unit128.

In one embodiment, the building 100 includes a window 114 and a door126. The window 114 can be directly cut through the building blocks 116b. In addition, the window 114 can also include, for example, a clearplastic or glass. Likewise, the door 126 can be formed by cuttingthrough the building blocks 116 a, 116 b, and/or 116 c. However, aportion of the outer block 102 and/or the inner block 104 for thebuilding blocks 116 a, 116 b, and/or 116 c can remain uncut in order toprovide a hinge for the door 126.

In one embodiment, the building block 116 can be formed, for example,from one or more interlocking building units 174 as seen in FIG. 17 andone or more column units 176 as seen in FIG. 18. Each of theinterlocking buildings units 174 can have an interlocking section 170and an interlocking section 172. The interlocking section 170 of oneinterlocking building unit 174 can mate with the interlocking section172 of another interlocking building unit 174. For example, as seen inFIG. 19, the interlocking building unit 174 a includes interlockingsections 170 a and 172 a, while the interlocking building unit 174 bincludes interlocking sections 170 b and 172 b. The interlockingbuilding unit 174 a can be connected to the interlocking building unit174 b by connecting the interlocking section 172 a and the interlockingsection 170 b together.

The column unit 176 can be inserted between the interlocking buildingunit 174 a and the interlocking building unit 174 b in the area occupiedjointly by the interlocking sections 172 a and 170 b. This prevents, forexample, the interlocking sections 172 a and 170 b from becomingseparated and substantially locks them in place. As seen in FIG. 20, theprocess can be repeated to form the building block 116, which can hold,for example, support material.

In one embodiment, the outer panel 102 can be physically bonded to theexpanding foam material 124 as shown in FIG. 38. As seen in FIG. 38, theouter panel 102 can be, for example, a 0.5 inch twin-wall sheet stock.The outer panel 102 can include an inner side 160 and an outer side 161,and a plurality of ribs 158. The plurality of ribs 158, the inner side160, and the outer side 161 define a plurality of hollow sections 182.The inner side 160 defines a plurality of holes 180, which allow theexpanding foam material to enter the hollow sections 182. By enteringthe hollow sections 182, the expanding foam material 124 forms aphysical bond with the outer panel 102. This can allow, for example, theexpanding foam material 124 to be secured to the outer panel 102. Theprinciples depicted in FIG. 38 can be applied, for example, to the innerpanel 104 to form a physical bond between the expanding foam material124 and the inner panel 104.

In one embodiment, the outer panel 102, the inner panel 104, the roof118, and/or the floor 122 can be formed, for example, from a foldingsection 136 as seen in FIG. 21 and FIG. 22. As seen in FIG. 21, thefolding section 136 can be folded into a compact position, while in FIG.22, the folding section 136 can be switched into an expanded position.By placing the folding section 136 in the compact position, it can beeasily transported allowing for more folding sections 136 to be placedin a small area. However, when the folding section 136 is ready to beused as an outer panel 102, inner panel 104, roof 118, and/or floor 122,it can be switched to the expanded position. The folding section 136 canbe sewn or joined together with stringers.

In one embodiment, the outer panel 102, the inner panel 104, the roof118, and/or the floor 122 can be formed, for example, from a foldingsection 138 as seen in FIG. 23, FIG. 24, FIG. 25, and/or FIG. 26. Asseen in FIG. 23, the folding section 138 can be a variety of differentshapes, such as a pentagon. As seen in FIG. 24 and FIG. 25, the foldingshape 138 can also be moved from a compact position to an open positionand/or stored in a compact position by being folded. As seen in FIG. 26,the folding shape 138 can be laid out in an expanded position as shownin FIG. 26. In such a case, the folding shape 138 can be desirable asthe roof 118.

The roof 118 can also be a variety of shapes as shown in FIG. 27, FIG.28, FIG. 29, and/or FIG. 30. The roof 118 can be designed, such that itcan still be folded and stored in a compact position or switched to anexpanded position when it is ready to be used. This can allow largerroofs to be implemented, even through the use of a standard 8 feetshipping container. Furthermore, the unconventional shapes can allow forgreater overhang of the roof 118 in the building 100 as shown in FIG.31. The overhang can allow water or other material to be drained away ata distance from the building block 116. This can reduce a likelihood ofdamage to the building block 116 and/or the building 100.

In one embodiment, the building block 116 can be expanded into a varietyof shapes in the expanded position as shown in FIG. 32. For example, thebuilding block 116 can be expanded into a figure-8. However, thebuilding block 116 can also be expanded into other shapes, such astriangle, octagon, circle, or any other type of shapes that are suitablefor a building.

In one embodiment, the roof 118 can be secured to the building block byusing roof anchors 142 as shown in FIG. 33. The roof anchors 142 can bepunched through the roof 118 and/or be aligned with a hole in the roof118. The roof anchors 142 can include, for example, a threaded portion178, which can then be mated with a threaded nut 176 to secure the roof118 between the threaded nut 176 and the building block 116. In oneembodiment, the roof 118 can be engaged to the building block 116before, or after support material 110 and/or expanding foam material 124has been placed in the roof 118.

In one embodiment, the roof 118 need not be formed to be flush with thebuilding block 116 as shown in FIG. 34. Instead, the roof 118 can be,for example, accordion shaped. Inserts 144 can be used in conjunctionwith the roof 118 and the building block to fill in the gaps between theroof 118 and the building block 116. Thus, the roof 118 can be slanted,pitched, irregular, and/or have a variety of sizes and shapes with theuse of the inserts 144 to reduce the gaps between the roof 118 and thebuilding block 116. The inserts 144 can be of a variety of sizes andshapes to fill in the gap between the roof 118 and the building block116.

In one embodiment, the roof 118 can include drains 146 to aid indraining the rainwater on the roof 118 as shown in FIG. 35. The drains146 can align, for example, with a conduit 112 (FIG. 1). The drains 146and/or the conduit 112 can be inside the building 116, between the outerpanel 102 and the inner panel 104, and/or outside the building 116. Thedrains 146 and/or the conduit 112 can be formed, for example, frompolypropylene or any other mildew or rot resistant material.

In one embodiment, the present invention is a process as shown in FIG.36. In Step 3602, a first building block is transformed from a compactposition to an expanded position. For example, the building block 116 acan be transformed from a compact position to an expanded position.(FIG. 13) In Step 3604, support material is placed in the first buildingblock. For example, supporting material 110, or expanding foam material124 can be placed in the support material area 116 a. In Step 3606, asecond building block is transformed from a compact position to anexpanded position. For example, the building block 116 b is transformedfrom a compact position to an expanded position. (FIG. 13) In Step 3608,the first building block is connected with the second building block.For example, the building block 116 a can be connected to the buildingblock 116 b. (FIG. 13)

In another embodiment, the present invention is a process according toFIG. 37. In Step 3702, only a single building block is transformed froma compact position to an expanded position. For example, a buildingblock 116 can be transformed from a compact position to an expandedposition. (FIG. 1) In Step 3704, support material is placed in thebuilding block. For example, the support material 110 can be placed inthe building block 116. In Step 3706, a roof can be transformed from acompact position to an expanded position. For example, the roof 118 canbe transformed from a compact position to an expanded position. (FIG. 4)In Step 3708 the roof is connected to the single building block. Forexample, the roof 118 can be connected to the building block 116. (FIG.4)

In another embodiment, the present invention can be, for example, abuilding kit. The building kit can include, for example, only a singlebuilding block 116, a roof 118, a first mixing material 150, and/or asecond mixing material 152. The single building block 116 and/or theroof 118 can be packaged in a compact position. This can, for example,reduce transportation costs and/or storage costs for the building kit.Furthermore, the first mixing material 150 and/or the second mixingmaterial 152 can be stored in substantially flat tubes to also reducetransportation costs and/or storage costs. Thus, the building kit cantherefore be a low-cost and easy solution for a user who wishes tobuild, for example, a small structure. The compact size of the buildingkit can reduce transportation and/or storage costs which can reduceoverhead costs for a merchant selling the building kit. Part of thereduction in overhead costs can be passed onto the consumer so that theconsumer can also partake in such savings. In addition, the consumerwill also enjoy savings in other manners since the building kit canreduce an amount of time and resources that it takes to build abuilding.

In addition, the building block 116 can also be used for otherapplications, such as for maritime uses, road barriers, securitybarriers, insulation uses, ballistic uses, and/or any other type of useswhich can be suitable for the properties of the building block 116. Themaritime uses can be, for example boat hulls, docks, or any other typeof marine applications. Due to the ballistic properties of the buildingblock 116, the building block 116 can also have military uses, such asfor ammunition sheds, or any buildings which may be exposed toexplosions. In addition, the building blocks 116 can be used, forexample, to provide armor for a vehicle.

In another embodiment, the building 100 also be easily deconstructed toallow for the building 100 to be reused at another site. In the casethat the support material 110 is the expanding foam material, adissolving compound can be poured over the expanding foam material 124to dissolve the expanding foam material 124.

The previous description of the disclosed examples is provided to enableany person of ordinary skill in the art to make or use the disclosedmethods and apparatus. Various modifications to these examples will bereadily apparent to those skilled in the art, and the principles definedherein may be applied to other examples without departing from thespirit or scope of the disclosed method and apparatus. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive and the scope of the invention is, therefore,indicated by the appended claims rather than by the foregoingdescription. All changes which come within the meaning and range ofequivalency of the claims are to be embraced within their scope

1. A building block comprising: a first panel; a second panel opposingthe first panel; and a plurality of stringers connecting the first paneland the second panel, wherein the first panel, the second panel, and theplurality of stringers are configured to switch between a compactposition and an expanded position.
 2. The building block of claim 1wherein the first panel, the second panel, and the plurality ofstringers define a support material area.
 3. The building block of claim2 wherein the support material area is configured to receive a supportmaterial.
 4. The building block of claim 3 wherein the support materialis at least one of an expanding foam material, cement, organic material,rubble, earth, adobe, or plant matter.
 5. The building block of claim 4wherein the support material is an expanding foam material whichsubstantially completes its expansion prior to substantially setting. 6.A building comprising: a plurality of building blocks, each of thebuilding blocks including: a first panel; a second panel opposing thefirst panel; and a plurality of stringers connecting the first panel andthe second panel, wherein each of the building blocks is configured toswitch between a compact position and an expanded position.
 7. Thebuilding of claim 6 wherein each of the building blocks further includesa plurality of ribs located within the first panel and the second panel.8. The building of claim 7 wherein the building blocks includes a firstbuilding block and a second building block, and the first building blockis connected to the second building block by connecting the ribs in thefirst building block and the ribs in the second building block.
 9. Thebuilding of claim 6 each of the building blocks is configured to includean expandable foam material.
 10. A building kit comprising: a buildingblock in a compact position; a first mixing material; and a secondmixing material, the first mixing material and the second mixingmaterial selected such that a mixture of the first mixing material andthe second mixing material forms an expandable foam material which canbe placed within the building block.
 11. The building kit of claim 10wherein the building block is configured to switch between the compactposition and an expanded position, and the expandable foam material isplaced within the building block when the building block is in theexpanded position.
 12. The building kit of claim 10 wherein the buildingblock includes a first panel, a second panel opposing the first panel,and a plurality of stringers connecting the first panel and the secondpanel.
 13. The building kit of claim 10 further comprising a pluralityof anchors configured to be attached to the building block.
 14. A methodfor constructing a building comprising: transforming a first buildingblock from a compact position to an expanded position; placing supportmaterial in a support material area in the first building block;transforming a second building block from a compact position to anexpanded position; and connecting the first building block with thesecond building block.
 15. The method of claim 13 wherein the supportmaterial is an expanding foam material.
 16. The method of claim 15further comprising mixing a first mixing material with a second mixingmaterial to form the expanding foam material.
 17. The method of claim 15further comprising removing excess expanding foam material when theexpanding foam material is substantially set.
 18. A method forconstructing a shed comprising: transforming only a single buildingblock from a compact position to an expanded position; placing supportmaterial in a support material area in the building block; transforminga roof from a compact position to an expanded position; and connectingthe roof to the single building block.
 19. The method of claim 18further comprising: forming a door from the single building block. 20.The method of claim 18 further comprising mixing a first mixing materialwith a second mixing material to form the support material.